Professional Documents
Culture Documents
Formwork Technology
Formwork Technology
December 2004
Table of contents
1.0 Product features 2.0 Overview 3.0 Components 4.0 Use and erection 5.0 Stripping 6.0 Stripping and transport aids 7.0 Tables for shuttering panels 8.0 Load tables for H20 9.0 H20 shuttering example 10.0 Load tables for props
2 3 47 817 18 19 20 21 22 23
2.0 Overview
Quick lowering mechanism: Another special feature is that all the props are equipped with the patented quick-release bolt, which, with a blow of the hammer, immediately releases the adjustment nut.
Beam end
dimensions in [cm]
4 3.4 5 22.5
6 cm using the adjustment nut of the steel props. With the space which results from the first lowering and by tilting the timber beams, the shuttering material can be systematically removed, while going easy on materials. (Subject to technical modifications.) 3
3.0 Components
Description Art. No Weight kg/pcs.
H 20
H 20 Beam 190 H 20 Beam 245 H 20 Beam 265 H 20 Beam 290 H 20 Beam 330
581 760 581 770 581 781 581 792 581 807 581 818 581 829 581 830 581 840 581 851 582 319
9.50 12.25 13.25 14.50 16.50 18.00 19.50 22.50 24.50 29.50 59.50 5.00
20
H 20 Beam 590 H 20 Beam 1190 H 20 beams in special lengths up to 12.00 m - per running metre Lengths < 1.90 m / > 7.90 m without drill holes and
Props
14 8 1.4 dia 12 1.4 dia 1.0 dia
rounded ends. Timber formwork beams with a height of 20 cm and a width of 8 cm. The H 20 beam is approved for the following statical figures: Max. perm. M = 5.00 kNm Max. perm. Q = 11.00 kN E I (bending stiffness) = 500 kNm
Europlus props
max. 5.50 m
260 DB/DIN (L = 1.54 - 2.60 m) 300 DB/DIN (L = 1.72 - 3.00 m) 350 DB/DIN (L = 1.98 - 3.50 m) 400 EC 550 DC (L = 2.24 - 4.00 m) (L = 3.03 - 5.50 m)
Alu props Alu 500 DC ( L = 2.80 - 5.00 m) 558 898 23.2 Lightweight aluminium prop with rectangular
2.79 - 5.00 m
14 17
Description
Art. No
Weight kg/pcs.
Beam Formwork
Joist clamping connector Can be fastened to any timber beam like H 20 and R 24 with 8 cm wide and at maximum 6 cm thick flanges (see page 12-16). 496 469 6.5
Adjustable fixing beam 500 This is fastened with the unlosable bolt to the joist clamping connector in steps of 1 cm corresponding to the required beam height. The position of the bolt is secured by means of a spring cotter (see page 12-16).
496 458
4.5
Triangular fillet (UZ) Used for beam formwork with 21 mm thick plywood panel. Length : 2.50 m
547 555
0.5
Accessories
Tripod stand 83 Simplifies the erection of Europlus and AS props for soffit formwork assembly. Only to be used as an erection aid; does not replace the stiffening necessary for the supporting structure.
510 256
11.5
Fork head 8/20 19.4 Protects H 20 beams which serve as primary beams from falling. Holds either 1 or 2 beams. Is secured in the prop with the T-bolt.
16. 9
417 565
12.5
8.4
3.0 Components
Description Art. No Weight kg/pcs.
Steel prop hanger 8 Helps to attach an additional prop to the H 20 beam (see page 9).
510 749
0.5
5.8
T-bolt (with spring) For securing the inserted fork heads and steel prop hangers (1 each). Can be used with
470 804
0.2
1.5
9.4
Europlus and AS props. See page 8. T-bolt Alu 500 Used for aluminium prop Alu 500 DC and Europlus props 400 EC and 550 DC. See page 8. 569 384
0.2
1.2
Bracing clamp Z
573 810
1.8
52
Attaches stiffening shutterboards to any tubular steel props. (For max. board thickness of 3 x 12 cm)
Combi-post Inserted in the universal joint, to guard against falls (see 11).
571 833
3.0
120
571 947
0.4
15
Slipped on the railing post before mounting it to the universal joint. The retainer secures the toe board.
Universal joint Is clamped on the H 20 beam. Holds railing posts and end shuttering (see 11).
569 476
3.5
20
6
Description
Art. No
Weight kg/pcs.
(Package 75 m)
569 708
800.0
(Package 100 m)
569 719
1060.0
Thickness 21 mm, L = 2.00 m, W = 0.50 m. Assembly fork Simplifies the laying and removal of H 20 shuttering beams.
10.5
Assembly fork
510 554
3.5
18
Simplifies the laying and removal of H 20 shuttering beams (see page 9).
150
Euro stacking frame 120/80 Steel, hot-dip galvanized Load-bearing capacity: 1200 kg For storing and transporting scaffolding and formwork materials. A maximum of 6 stands can be stacked.
80
120
Euro stacking frame 120/80 Steel, hot-dip galvanized Load-bearing capacity: 1200 kg For storing and transporting scaffolding and formwork materials. A maximum of
553 689
54.9
80
Mobile-set To manoeuvre the Euro stacking frame. Is simply slotted into the stacking frame, which can then even be moved when loaded (Working load: 1,300 kg). See page 19.
563 722
32.3
Prop with fork head 8/20 To begin with, the fork heads 8/20 have to be attached to the tubular steel props. The inserted heads are secured with a T-bolt. Both fork heads have a 2-way design. This means that in one position one timber beam, and in the other position - a 90 rotation - two timber beams can be inserted in the head (assuming a 8 cm beam width).
T-bolt
Prop with tripod stand The tripod stand makes it easier to set up the tubular steel props during erection. The prop is simply set in the open stand and secured through the clamping loop with a gentle blow of the hammer. The tripod stand can be used with all types of props. The flexibly mounted supporting legs of the tripod stand permit an optimal fit, even in the corners of the structure. Important note After the soffit formwork has been completely erected in the room or area, the tripod stand can be removed and shifted to the next erection site. It serves only as an aid in assembling the slab formwork. 62 112 ~ 85
Erecting the primary beams Erection of the Variomax soffit formwork begins with setting up the primary beams. For this, the props are set at roughly the required extension length on the ground. The fork heads are mounted to them, and then they are set up under the ends of the primary beams (in the case of jointed beams, under the joints as well). To keep them steady, tripod stands are attached to these props.
Assembly fork
Following this, the H 20 beams are placed in the fork heads of the props. The assembly forks make this step much easier. Then the remaining props should be set up, taking into account the static requirements (room height, slab thickness, and maximum permitted loading capacity of the tubular steel props which are being used). The steel prop hangers which are attached to the props immediately safeguard them from falling over. The prop is then swung into place under the primary beam. T-bolt
Placing the secondary beams The correct distance between the secondary beams must be calculated, in line with the static requirements, by using the loading tables on pages 20 and 21. A beam must be placed under each shuttering panel joint. Here, too, the work is facilitated by the assembly fork.
Adding the shuttering panels The shuttering panels are placed on top of the secondary beams and tacked in place. The rigid shuttering structure must be braced against the building.
Note: Safety rails must be erected on the edges of the structure, in line with the regulations for safety and health protection in shuttering and scaffolding ZH1/ 603.
10
The universal joint, with its simple and effective wedge connection, can be secured at any place on the H 20 beam. It is equipped with a socket for the Combi-post. The universal joint can also be used as a supporting bracket for shuttering the stop-end of a slab or an integrated beam.
Combi-post
Universal joint
H 20 beam
The illustration shows shuttering of the stop-end of a slab, which is also a safety guard. The Combi-post has 2 alternative positions. 120
140
11
Joist clamping connector Can be fastened to any timber beam like H 20 and R 24 with 8 cm wide and at maximum 6 cm thick flanges. Adjustable fixing beam 500 This is fastened with the unlosable bolt to the joist clamping connector in steps of 1 cm corresponding to the required beam height. The position of the bolt is secured by means of a spring cotter
H20 beam
distance
Permissible distances Joist clamping connectors are only to be arranged opposite on top of the same transverse beam. H The height " H " of the side formwork is decisive for the calculation. In case of having perimeter beams, the exterior side is decisive for the permissible distances. H beam height H (cm) 30 35 t H 40 45 50 55 60 H 65 70 75 80 H 85 90 max. distances of joist clamping connectors without slab [m] 2.25 2.00 1.75 1.50 1.35 1.30 1.05 0.90 0.80 0.60 0.55 0.45 0.35 [m] 1.50 1.25 1.05 0.95 0.85 0.75 0.65 0.50 0.40 0.30 with slab t = 20 cm t = 30 cm [m] 1.25 1.00 0.90 0.80 0.70 0.60 0.50 0.40 0.35
12
4 Erect the longitudinal main supports ( 1 ). Place transverse beams ( 2 ) on main beams. Nail bottom shuttering skin ( 3 ) on beams ( 2 ). Place and attach side shuttering skin ( 4 ). Put on timber beam ( 5 ) or squared timber. Position joist clamping connector ( 6 ) on top of the cross beam ( 2 ), press it against side formwork ( 4+5 ) and tighten wing nut by means of a hammer. Fix the adjustable fixing beam ( 7 ) acc. to the desired height of beam formwork. Place upper timber beam ( 8 ) on the angle iron welded to the fixing beam ( 7 ). Erection of opposite side shuttering ( 9 ) after reinforcement work. Same procedure as already described before. 9 Note: Always arrange the joist clamping connector in opposite position on the same transverse beam. 6 1 2 3
13
Joist clamping connector and Adjustable fixing beam Can be fastened to any timber beam like H20 and R24 with 8 cm wide and at maximum 6 cm thick flanges.
Plank
Slab stopend
Joist clamping connector
14
1 1 1 1 1
H 20 has to be secured from horizontal slipping
out.
The exterior side shuttering (here in this example) is formed by means of vertically arranged H 20 inserted in the C-profile of the joist clamping connector. The application of the adjustable fixing beam is not required with this design.
Joist clamping connector Adjustable fixing beam 500 Joist clamping connector
T-intersections and crossings of beams Even in these areas it is possible to work with the joist clamping connector easily and without problems and without costly fitting work. It is only to be noted that the transverse beams must not project more than 35 cm into the cross beams of the rectangularly arranged beam formwork of the intersection. max. 35 cm
15
When joining timber beam slab formwork and beam formwork, two connecting variations arise through the directions of the secondary beams of the slab formwork. Direction of secondary beam parallel to the beam formwork The top timber beam H 20 of the side shuttering of the beam is arranged in such a way with the secondary beams of the slab formwork that it serves as support beam for the plywood of the slab at the same time. The top timber beam H 20 of the side shuttering of the beam is lowered to such a degree that the secondary beam can directly be placed on this.
pre-fabricated slab Other slab formwork systems can be bound into the beam formwork without any problems thanks to the height adjustment possibility of the adjustable fixing beam. Important note: Maximum slab load per each joist clamping connector: 6.5 kN
Topec-formwork
16
Shuttering procedures
1. Secure fork head or drophead in the props. 2. Set up tripod stands (at least 4 in the corners of the room, plus additional units for primary beam joints.) 3. Secure the props in the tripod stands. 4. Lay the primary beams in the fork heads. 5. Attach additional props and steel prop hangers, in line with the table on page 12, under the primary beams. 6. Lay secondary beams. 7. Lay shuttering panels. 8. If necessary, set up auxiliary props under the infill panels, in line with DIN 1045.
Infill panel
Secondary beam
Shuttering panels
Primary beam
17
5.0 Stripping
Stripping begins with lowering the props. For all tubular steel props from HNNEBECK, release bolts immediately reduce the pressure on the thread nut. A blow of the hammer suffices and then the slab shuttering can easily be lowered by about 6 cm turning down the adjustment nut.
H20 beam
quick-release bolt
The assembly fork is an effective tool for taking down the primary beams. Remove the tripod stands from the props, and sort and stack all of the shuttering materials.
18
The shuttering materials are stored and transported in the practical Euro stacking frames. With the mobile set, which can be attached quickly, the materials can be brought within the range of the crane. The Euro stacking frame is designed for a working load of 1,200 kg. It can be moved with a crane, fork lift or the mobile set, which has a loading capacity of 1,300 kg. Up to 6 loaded frames may be stacked.
Main wheel
Supporting wheel
The two main wheels of the mobile set are easy to mount, simply by inserting their axles into the sockets in the stacking frame. A swing of the wheel lever lifts the stacking frame, and the swivel safety handle keeps the wheel lever in this position. A supporting wheel which is inserted at the front of the stacking frame stabilizes the running gear.
19
20 25 30 62
20
Table III Max. permitted span for secondary beams L in m = Max. primary beam spacing. Systems: (Max. K = 0.50 m)
K K
L
Select slab thickness Determine secondary beam spacing "e" (m) taking into account type of shuttering panel (see page 20). Determine max. span of secondary beam (this is equal to distances between primary beams). Determine final distance between primary beams taking into account the allowable deflection of secondary beams. Determine prop spacing for axes of primary beams taking into account the loading width (Edge section with/without cantilever and centre section).
/2
c)
b)
/2
/2
L
perm. L
perm. L
/2
/2
( max. K = 0.50 m)
2
Secondary beam spacing [m] (unter Beachtung von Seite 20)
3
Gewhlter Jochtrgerabstand bzw. Belastungsbreite L [m]
0.40
0.50
0.63
0.67
0.75
1.00
1.25
1.50
1.75
2.00
2.25
2.50
3.00
3.50
4.00
4.50
Zul. Sttzenabstand unter Jochtrgern [m] (a, b oder c gem. Seite 11)
10 12 14 16 18 20 22 24 26 28 30 40 50
4.35 4.87 5.39 5.91 6.43 6.95 7.47 7.99 8.51 9.03 9.61 12.73 15.85
3.99 3.78 3.60 3.45 3.33 3.22 3.12 3.04 2.96 2.89 2.83 2.57 2.39
3.71 3.51 3.34 3.21 3.09 2.99 2.90 2.82 2.75 2.68 2.62 2.39 2.22
3.44 3.26 3.10 2.98 2.87 2.77 2.69 2.62 2.55 2.49 2.44 2.22 2.01
3.37 3.19 3.04 2.91 2.81 2.71 2.63 2.56 2.50 2.44 2.38 2.17 1.95
3.24 3.06 2.92 2.80 2.70 2.61 2.53 2.46 2.40 2.34 2.29 2.05 1.83
2.94 2.71 2.78 2.56 2.65 2.44 2.54 2.33 2.45 2.23 2.37 2.15 2.30 2.07 2.24 2.00 2.17 1.94 2.10 1.88 2.04 1.82 1.73 1.38 1.39 1.11
2.48 2.34 2.22 2.12 2.04 1.96 1.89 1.83 1.72 1.62 1.53 1.15 0.93
2.29 2.17 2.06 1.97 1.89 1.81 1.68 1.57 1.48 1.39 1.31 0.99 0.79
2.14 2.03 1.93 1.84 1.71 1.58 1.47 1.38 1.29 1.22 1.14 0.86 0.69
2.02 1.91 1.81 1.65 1.52 1.41 1.31 1.22 1.15 1.08 1.02 0.77 0.62
1.92 1.81 1.63 1.49 1.37 1.27 1.18 1.10 1.03 0.97 0.92 0.69 0.56
1.69 1.51 1.36 1.24 1.14 1.06 0.98 0.92 0.86 0.81 0.76 0.58 0.46
1.44 1.29 1.17 1.06 0.98 0.90 0.84 0.79 0.74 0.70 0.65 0.49 0.40
1.26 1.12 1.13 1.00 1.02 0.91 0.93 0.83 0.86 0.76 0.79 0.70 0.74 0.65 0.69 0.61 0.65 0.57 0.61 0.54 0.57 0.51 0.43 0.38 0.35 0.31
(*) Total load assumed in the following way: Weight of concrete 25 kN/m Concrete load 26.0 t [kN/m] Dead load of formwork 0.25 kN/m Live load 1.50 kN/m Total load = Concrete load + Dead load of formwork + Live load (**) Deflections of secondary beams are limited to: f < L/300 (first line) - f < L/500 (second line)
Prop loads
"Q" decisive
In most cases, the max. permitted prop spacing under primary beams, as stated in Table III, Column 3 , results from the perm. shear load "Q" of the H20 timber beam (2 11.0 kN = 22.0 kN = suport load for the steel prop). In this case, the following has to be considered: If the permitted load "F" of the prop is less than 22.0 kN, the prop spacing under the primary beams should be reduced by the factor "max. perm. F/22.0 kN". (See also the example on page 14 under IV. Remark.)
Note:
The maximum permitted prop load in relation to the extension length can be found in the Hnnebeck Folding Table with allowable loads for tubular steel props.
21
II.) Determining the max. perm. span for secondary beams In Part 2 of Table III on page 21, find where the 16 cm slab thickness row intersects with the 0.75 cm secondary beam spacing column, to obtain the maximum permitted span of 2.85 m (= max. primary beam spacing with f < L/500). III.) Determining the max. perm. span for primary beams In Part 3 of Table III, the first horizontal column shows the desired primary beam spacings and thus also the loading widths. For example, for a room width of 3.50 m, primary beams RJ1 and RJ2 (see ground-plan) have a loading width of 1.75 m. By seeing where the 1.75 m column intersects with the 16 cm slab thickness row, you obtain the max. prop spacing of 2.0 m for the edge section beam. For the centre section beam MJ, taking into account the loading span of 2.5 m, the max. permitted prop spacing is calculated at 1.53 m (= max. prop spacing).
Section B - B
Secondary beam (As per Table II)
Section A - A
e= 75
e= 75
H = 2.60 m
max. 2.0
max. 1.53
max. 1.53
max. 1.53
max. K = 50 cm
RJ3 RJ1 MJ Selected: 2.50 50 50 Selected: 2.50 (max. 2.85) (max. 2.85) 6.00
Materials summary
(example)
No. Description H 20 - 245 H 20 - 290 H 20 - 330 H 20 - 450 Props 260 DB/DIN Fork head 8/20 Steel prop hanger Tripod stand Suggested: T-bolt Assembly fork Euro stacking frame Mobile Set Art.No. 581 581 581 581 770 792 807 830
e= 75
H 20 450
B
50
H 20 450
RJ1
H 20-290
H 20-330
H 20-290
RJ2
H 20 450
H 20-330
H 20 450
max. 1.53 m
2.50
6.00
MJ
2.50
max. 2.0 m
2 6 13 4 14 9 5 9
RJ3
B
3.80 4.40
max. 2.0 m
22
50
H 20 245
H 20 245
RJ3
14 2 2 1
2.50
Loading width
(As per Table III)
550 DC
350 EC/DIN
Size
extension length [m]
Size
extension length [m]
1
1.54 2.60 m
2
1.72 3.00 m
3
1.98 3.50 m
4
2.34 4.10 m
5
2.50 4.50 m
Size
extension length [m]
7
3.03 5.50 m
3
1.98 3.50 m
35.00 35.00 35.00 35.00 35.00 33.60 31.07 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00
4
2.24 4.00 m
35.00 35.00 35.00 35.00 35.00 32.92 30.61 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00 30.00
1.50 1.60 1.70 1.80 1.90 2.00 2.10 2.20 2.30 2.40 2.50 2.60 2.70 2.80 2.90 3.00 3.10 3.20 3.30 3.40 3.50 3.60 3.70 3.80 3.90 4.00 4.10 4.20 4.30 4.40 4.50
30,00 30.00 30.00 30.00 28.81 26.00 23.58 21.49 20.00 20.00 20.00 20.00
30.00 30.00 30.00 30.00 27.21 24.79 22.68 20.83 20.00 20.00 20.00 20.00 20.00 20.00
30.00 30.00 28.93 26.47 24.31 22.40 20.71 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
30.00 28.47 26.24 24.26 22.50 20.92 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20,00 20.00 20.00 20,00
28.80 26.63 24.69 22.96 21,40 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
3.00 3.10 3.20 3.30 3.40 3.50 3.60 3.70 3.80 3.90 4.00 4.10 4.20 4.30 4.40 4.50 4.60 4.70 4.80 4.90 5.00 5.10 5.20 5.30 5.40 5.50
35.00 34.34 32.23 30.30 28.55 26.94 25.46 24.11 22.85 21.70 20.63 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
2.00 2.10 2.20 2.30 2.40 2.50 2.60 2.70 2.80 2.90 3.00 3.10 3.20 3.30 3.40 3.50 3.60 3.70 3.80 3.90 4.00
2.2
B. Dimensions
Props used for housing construction: e.g. Europlus 260 DB/DIN 0.5 pcs./m 7.8 kg/m
Props used for industrial construction: e.g. prop AS 410 DIN 0.6 pcs./m 1.7 kg/m 23
400 EC
Hnnebeck GmbH P O. Box 104461, D-40853 Ratingen, Germany . Phone +49 (0) 2102/937-1, Fax +49 (0) 2102/37651 info@huennebeck.com, www.huennebeck.de
GB-12-04-1000-DDH